Biomimetic and variable stiffness ankle system and related methods

ABSTRACT

A cam system for an assistive device and related methods are disclosed. The cam system may comprise a cam profile and a cam follower. The cam profile has a curved outer edge comprising a concave portion. The cam follower is positioned within the concave portion when the assistive device is in an equilibrium position. The assistive device may further comprise a spring that deflects in response to a force applied by the cam system. The assistive device may have a sliding element to adjust the stiffness of the spring in deflection. The assistive device may take the form of a prosthesis or an orthosis.

RELATED APPLICATIONS

This application claims benefit to U.S. Provisional Patent Application No. 62/403,597 filed on Oct. 3, 2016 and U.S. Provisional Patent Application No. 62/412,583 filed on Oct. 25, 2016, both of which are incorporated by reference.

BACKGROUND

Ankle-foot prostheses are used by individuals who do not have an ankle. Many commercially available prosthetic ankle-feet behave much like springs, storing and returning energy to the wearer. However, the torque-angle relationships of these prostheses do not appropriately follow the torque-angle relationship (or “quasi-stiffness” curve) of able-bodied walking.

Some ankle-foot prostheses, such as a Solid Ankle-Cushion Heel (SACH) Foot, are stiffer during stance phase than a human ankle would be in a similar phase. Other ankle-foot prostheses, such as Energy Storage and Return (ESR) feet, are less stiff, but do not appropriately mimic the low quasi-stiffness during early stance, and the rapidly increasing quasi-stiffness before heel-off. This may in part be due to the difficulty of designing devices with nonlinear stiffness characteristics. As a result of the relatively high stiffness during mid-stance of such prostheses, the individual's tibial progression is hindered, which may slow the self-selected walking speed. The relatively high stiffness of such prostheses during controlled plantarflexion immediately following heel strike may also prolong heel-only contact, reducing stability and inhibiting tibial progression.

ESR feet are also unable to modulate their mechanical properties to improve function during other mobility tasks. For instance, during quiet standing, transtibial amputees exhibit increased postural sway. Additionally, ESR feet exhibit significantly reduced range of motion during stair traversal, likely due to their high stiffness making forward progression of the center of mass more difficult. In addition, they are unable to capture the change in potential energy of the center of mass that results from tibial progression. For these tasks, amputees develop abnormal compensatory gait patterns which can lead to a wide range of issues, such as socket pain, back pain, and joint diseases.

Some ankle prostheses vary damping characteristics. Changing ankle mechanics with damping variation may be counterproductive, since energy is being removed from the ankle joint, which provides a majority of the mechanical energy needed for forward propulsion in able-bodied gait.

It would be useful for an ankle-foot prosthesis to exhibit appropriate biomechanics during various phases of gait, such as walking, stair traversal, or quiet standing. Likewise, it would be useful for other assistive devices, such as orthoses, to help patients exhibiting similarly appropriate biomechanics using their sound limbs.

BRIEF SUMMARY

A cam system for an assistive device is disclosed. The system may comprise a cam profile and a cam follower. The cam profile may have a curved outer edge comprising a concave portion. The cam follower may be positioned within the concave portion when the assistive device is in an equilibrium position.

The cam profile may be positioned to rotate about a joint of the assistive device in response to a force applied to the assistive device during a stance phase of gait.

The cam follower may be coupled to a leaf spring of the assistive device. The cam follower may roll along the curved outer edge of the cam profile from dorsiflexion to plantarflexion of the assistive device.

The cam profile may have a convex portion on which the cam follower is positioned during plantarflexion of the assistive device. The cam profile may have a convex portion on which the cam follower is positioned during dorsiflexion of the assistive device.

An assistive device comprising a cam system is disclosed. The assistive device may comprise a leaf spring. The cam system may be positioned at an end of the leaf spring such that a force applied to the cam system causes deflection of the leaf spring. The assistive device may comprise a sliding element to adjust the stiffness of the leaf spring upon deflection. The position of the sliding element may be adjustable along a surface of the leaf spring.

The sliding element may be positioned on a motor-powered screw that adjusts the position of the sliding element on the surface of the leaf spring. The position of the sliding element along the surface of the leaf spring may be manually adjustable. The assistive device may comprise a Bowden cable attached to the sliding element to manually adjust the position of the sliding element.

The assistive device may be an ankle prosthesis or an orthosis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following descriptions of the drawings and example assistive devices present certain aspects, wherein like reference numerals across the several views refer to identical or equivalent features, and wherein:

FIG. 1 displays a series of able-bodied ankle quasi-stiffness curves during stance phase, for level-ground walking, stair descent, and standing.

FIG. 2A displays a front view of an example ankle prosthesis.

FIG. 2B displays a side view of an example ankle prosthesis.

FIG. 2C displays another side view of the example ankle prosthesis.

FIG. 3A displays a first diagram of a mathematical description of the cam profile and the cam follower.

FIG. 3B displays a second diagram of a mathematical description of the cam profile and the cam follower.

FIG. 4A displays an illustration of how moving a simple support towards a load increases spring stiffness.

FIG. 4B displays a graph indicating experimental results of translational leaf spring stiffness as a function of the slider position.

FIG. 5 displays a graph that plots slider position as a percentage against time, depicting step responses from standing stiffness to other stiffnesses in an example of an ankle prosthesis.

FIG. 6 displays a graph that plots a primary desired quasi-stiffness curve for walking, wherein the shaded region reflects the range of possible stiffnesses.

FIG. 7 displays a series of plots that experimentally characterize stiffness profiles of an exemplary ankle prosthesis at different stiffness profiles.

FIG. 8 displays a representational diagram for a method of deriving a cam profile.

FIG. 9 displays a pictoral representation of a system for controlling an ankle prosthesis.

FIG. 10 displays a side view of an example passive ankle prosthesis.

FIG. 11 displays a side view of an example orthosis.

FIG. 12 displays a view of an exemplary cam profile with a curved outer edge.

DETAILED DESCRIPTION

“Dorsiflexion” is the flexion of a human ankle or an assistive device such that the angle between the foot and shin decreases. In dorsiflexion, the toes on a human foot point upwards towards the shin. A “dorsiflexion position” is a position of the ankle or assistive device when it is in dorsiflexion.

“Plantarflexion” is the extension of a human ankle or an assistive device such that the angle between the foot and the shin increases. In plantarflexion, the toes on a human foot point away from the shin. A “plantarflexion position” is a position of the ankle or assistive device when it is in plantarflexion.

An “equilibrium position” refers to the position of an assistive device when the assistive device is between a dorsiflexion position and a plantarflexion position.

“Stance phase” of gait refers to the phase of gait when a foot or prosthesis is touching the ground during gait.

“Swing phase” of gait refers to the phase of gait when the foot or prosthesis has left the ground.

Example ankle prostheses disclosed herein are designed to closely match human biomechanics during gait. The ankle prosthesis may comprise a cam-based transmission and a stiffness modulation unit. The cam-based transmission may comprise a cam profile, a cam follower, and a spring. The stiffness modulation unit can be adjustable to adjust the stiffness of the spring in the cam-based transmission. The cam profile may be machined to create a specific torque-angle relationship depending on the adjustment of the stiffness modulation unit. As used herein, the phrase “primary stiffness modulation unit position” refers to a pre-determined position of the stiffness modulation unit, and the “primary stiffness curve” refers to a specific torque-angle relationship provided by the ankle prosthesis when the stiffness modulation unit is at the primary stiffness modulation unit position.

A quasi-passive ankle-foot prosthesis is disclosed. The prosthesis employs a customizable torque-angle profile for gait. The ankle stiffness can be varied continuously. The ankle-foot prosthesis may comprise a cam-based transmission, in which rotation of the ankle joint in the prosthesis causes a cam follower to deflect a leaf spring, and a repositionable sliding support beneath the leaf spring that can change the beam's stiffness. In a preferred example, the mechanism is lightweight and fits into an anthropomorphic physical envelope. Ankle stiffness may be adjusted during the swing phase of locomotion, as well as between ambulation modes such as between standing and stair traverse. The cam profile may be designed on the basis of a mathematical model to create a desired stiffness profile.

Quasi-passive ankle-foot prostheses are disclosed. An example prosthesis employs a customizable torque-angle profile for gait. The ankle stiffness can be varied continuously. The ankle-foot prosthesis may comprise a cam-based transmission, in which rotation of the ankle joint in the prosthesis causes a cam follower to deflect a leaf spring, and a repositionable sliding support beneath the leaf spring that can change the beam's stiffness. In a preferred example, the mechanism is lightweight and fits into an anthropomorphic physical envelope. Ankle stiffness may be adjusted during the swing phase of locomotion, and between ambulation modes. The cam profile may be designed on the basis of a mathematical model to create a desired stiffness profile.

An example passive ankle-foot prosthesis employs a customizable torque-angle profile for gait. The ankle stiffness can be varied continuously. The ankle-foot prosthesis may comprise a cam-based transmission, in which rotation of the ankle joint in the prosthesis causes a cam follower to deflect a leaf spring, and a repositionable sliding support beneath the leaf spring that can change the beam's stiffness. In a preferred example, the mechanism is lightweight and fits into an anthropomorphic physical envelope. Ankle stiffness may be adjusted during the swing phase of locomotion, and between ambulation modes. The cam profile may be designed on the basis of a mathematical model to create a desired stiffness profile.

FIG. 1 displays a series of able-bodied ankle quasi-stiffness curves during stance phase, for level-ground walking, stair descent, and standing. The bolded portions of each curve indicate controlled dorsiflexion for walking, and heal strike to toe-off for stair descent. Standing stiffness is an estimate of the purely passive ankle stiffness required to explain sway dynamics in quiet standing. Positive torque is plantarflexive, positive angle is dorsiflexion.

FIGS. 2A and 2B display a front view and a side view, respectively, of an exemplary ankle prosthesis 201. The ankle prosthesis 201 comprises a cam-based transmission, in which a cam profile 252 at the ankle joint 205 compresses a leaf spring 210. In the example shown in FIGS. 2A and 2B, the stiffness modulation unit, and a slider 220, which actively modifies the support conditions of the leaf spring 210 to affect stiffness. For ambulation modes other than walking, the slider 220 can be repositioned along the length of the lead screw 232 to modify the shape of the torque-angle relationship to be more or less stiff, deviating from the primary stiffness curve. When the slider 220 is positioned closer to the attachment block 266, the stiffness of the leaf spring 210 increases. When the slider 220 is positioned further from the attachment block 266, the stiffness of the leaf spring 210 decreases. The slider 220 may comprise a roller or other bearing system to reduce friction between the slider 220 and the leaf spring 210.

A user wearing the ankle prosthesis 201 causes the ankle prosthesis 201 to rotate about the ankle joint 205 by placing a load on the ankle prosthesis 201—for example, when the user is walking and places the heel 265 into contact with the ground, the user transfers his or her weight onto the ankle prosthesis 201. As the user applies such a force, the upper frame 263 begins to rotate about the ankle joint 205 with respect to the frame 262. The cam profile 252 is rigidly affixed to the upper frame 263, such that the cam profile 252 likewise rotates around the ankle joint 205. As the cam profile 252 rotates, the cam follower 254 rolls along the cam profile 252, both during dorsiflexion and plantarflexion of the ankle prosthesis 201. Rotation of the prosthesis 201 at the ankle joint 205 causes downward deflection of the cam follower 254, which causes deflection of the leaf spring 210. This deflection causes a restoring torque at the ankle joint 205.

FIG. 2C displays a side view of the prosthesis 201 in a dorsiflexion position, while the leaf spring 210 is under deflection. A force is applied to the upper portion of the prosthesis 201 comprising adaptor 256, which causes the cam profile 252 to rotate about the ankle joint 205 205. Rotation of the cam profile 252 applies a downward force on the proximal end of the leaf spring 210, causing the deflection of the leaf spring 210 shown in FIG. 2C.

Cam Design. The cam profile 252 governs the relationship between angle of the ankle prosthesis 201 at the ankle joint 205, and the associated deflection of the leaf spring 210 (thus, governing the ankle torque-angle). The cam profile 252 can be machined to create a specific torque-angle relationship for the ankle prosthesis 201 based on the primary slider position. Exemplary mathematics governing the relationship between cam profile 252 and the ankle torque-angle curve are presented below.

In an example, the cam follower 254 has a diameter of 19 mm and a dynamic load rating of 4 kN (Misumi USA, Schaumburg Ill.). The cam profile 252 may be machined from an appropriate material, such as tool steel, which has a hardness and resistance to deformation. The cam profile 252 may be hardened to approximately 60 Rockwell C to prevent deformation from the high loads. The shape of the cam profile 252 corresponds to the primary stiffness curve, which mimics the able-bodied quasi-stiffness curve.

The cam profile 252 can be machined so that during a specific ambulation mode, such as walking, the cam profile 252 creates specific torque-angle relationship (the “primary stiffness curve”) at a specified position of the slider 220 (the “primary slider position”). For other ambulation modes, the slider 220 can be repositioned to modify the shape of the torque-angle relationship to be more or less stiff, deviating from the primary stiffness curve, for different ambulation modes, such as standing or stair descent.

Leaf Spring. To vary stiffness, the support condition of the leaf spring 210 can be actively varied continuously throughout the length of the leaf spring 210. The leaf spring 210 may be coupled to a clamp support 270 anteriorly towards the toe 274, and a slider 220 in the mid-foot region. A lead screw 232 positions the slider 220 along a range of motion so that the position of the slider 220 is adjustable along the bottom surface of the leaf spring 210, as shown in FIG. 2B. In an example, the lead screw may be a 6.35 mm diameter, non-backdriveable lead screw capable of dynamic loads up to 700 N, with 1.27 mm lead (Nook Industries, Cleveland, Ohio, USA), which is able to position the slider 220 along an 85 mm range of motion. A DC motor 230 powers the lead screw 232. In an example, the DC motor 230 is a 10 Watt brushed DC Motor (Maxon Motors, Switzerland) with a 3.9:1 planetary gearhead and capable of 25 mNm intermittently. The DC motor 230 also may have an integrated 1024 counts-per-revolution incremental encoder 260, which may be used for positioning of the DC motor 230.

The leaf spring 210 may be constructed from unilateral fiberglass (Gordon Composites, CO, USA). Fiberglass can be a useful material in this application because of its high energy-storing capacity, making it up to eight times lighter and smaller than an equivalent spring made of steel. The leaf spring 210 may be shaped for roughly equal stresses on the outer strands at the primary slider position. In a preferred example, the height of the leaf spring 210 varies, as shown in FIG. 2B, resulting in lower shear stresses and making it less likely for delamination to occur. In other examples, the width of the leaf spring 210 may be varied rather than or in addition to varying the height of the leaf spring 210.

The rotational stiffness of the leaf spring 210 can be derived from experimental results of translational spring stiffness, shown in FIG. 4, and the effective moment arm. To predict ankle stiffness curves at different leaf spring stiffnesses, which are generated by different slider positions, a forward model may be employed that reverses through the presented equations. The translational stiffness of the spring, position of the virtual spring pivot, and spring preload are adjusted to simulate movement of the slider.

The translational stiffness of the leaf spring as a function of slider position may be found using a material testing system, such as Sintech 20G (Singapore, Singapore). Over an order of magnitude of translational stiffness modulation may be possible within the slider's range of motion, for example, 0.17-2.8 kN/mm.

Mechatronics. FIG. 9 displays a representation of an exemplary mechatronic system used to power and control the electrical components of the prosthesis 201. The low-level positioning of the DC motor 230 may be performed by a motor controller 412, such as an EPOS2 motor controller (Maxon Motors, Switzerland). A computer 414, which may be a single board computer such as a Linux computer (Raspberry Pi Zero, Raspberry Pi Foundation, Cambridge, UK) sends desired position to the motor controller 412, for instance by a step-direction method. In a step-direction method, each pulse is scaled to move the slider 220 by a predetermined amount, such as 1 mm, which provides sufficient resolution for stiffness modulation. For example, the motor controller 412 may cause the motor encoder 260 to drive the DC motor 230 an appropriate amount to turn the lead screw 232, which moves the slider 220 the 1 mm length in the intended direction along the lead screw 232. The computer 414 also can read ankle position, measured by an encoder 258, such as a 14-bit absolute encoder (AS5048A AMS, Premstaetten, Austria), via an interface 416 such as a Serial Peripheral Interface. Stiffness modulation may be prevented when the ankle joint 205 is outside of a predetermined limit, such as ±1° of neutral, as measured by the encoder 258. When the ankle joint 205 is outside such a range, that indicates that the spring 210 is compressed beyond the preload, and movement of the slider 220 is not possible with the available torque provided by the DC motor 230. The computer 414 can communicates with a host computer 424 over known communication protocols, such as Wi-Fi. A battery 426, such as a 14.8 V, 430 mA-hour Lithium-Polymer battery (Venom, Rashdrum, ID, USA) powers the motor controller 412, the computer 414, any associated electronics, and the DC motor 230. The computer 414, motor controller 412, and battery 426 may be housed in an electronics box 405, which can be mounted to the prosthesis socket, making the design entirely mobile for non-tethered operation.

To alter mechanics during swing phase, the slider 220 needs to reposition quickly. The reference position may be modified by the computer 414, which sends the appropriate command to the low-level motor controller 412 via the step-direction method. Step responses from the highest stiffness (100%) to several stiffnesses are shown in FIG. 5. Specifically, FIG. 5 depicts a graph plotting step responses from standing stiffness (100%) to other stiffnesses. The dashed line in FIG. 5 denotes the step response to the slider position of the primary stiffness (47%). The maximum speed of the slider is 80 mm/s, and is limited by the motor and gearhead's maximum permissible speed. Desired position, actual position, and current were recorded by the EPOS2 Studio software (Maxon Motors, Switzerland).

Frame. In addition to impact forces and the weight of the person using the prosthesis 201, there can be large forces in the frame 262 from the high loads on the leaf spring 210. The frame 262 may therefore be constructed from a material of high strength, high stiffness, and low weight, such as 7075-T6 Aluminum. The ankle joint 205 may have mechanical hard stops, for instance at 30° of plantarflexion and 30° dorsiflexion. Angular contact bearings can support the cam profile 252. The prosthesis 201 may be attached to a socket worn by an amputee via an adaptor 256, such as a titanium pyramid adaptor with rotational adjustability (Bulldog Tools, Inc., Lewisburg, Ohio, USA).

Cam Design—Mathematical Modeling. In order to obtain the primary stiffness curve for the ankle prosthesis 201, an appropriate cam profile 252 may be designed. A summary of an exemplary strategy for derivation of the cam profile 252 can be summarized as follows, and is shown in FIG. 8. In 801, the leaf spring 210 may be modeled as a rotary spring centered at a simple support. In 802, the problem may be framed using the principle of virtual work, where the energy stored in the ankle prosthesis 201 is equal to the energy stored in the spring. In 803, solve for rotational deflection of the spring. In 804, use the geometry to determine cam radius from ankle angle and spring angle. In 805, convert from ankle space to cam coordinates.

FIG. 3A and FIG. 3B display diagrams that reflect a mathematical description of the cam profile and the cam follower. The cam follower is simplified to a point (indicated by the triangle 301). Downward deflection of the cam follower (γ) is resisted by the leaf spring (M_(S)), which has a ‘virtual pivot’ located at the simple support/slider, and is considered a rotational spring. Deflection of the ankle (θ) causes a moment at the ankle (M_(A)), produced by the force between the cam follower and cam profile. The leaf spring is preloaded a small angle γ0 (the unpreloaded position is shown). FIG. 3B reflects the geometry used to find the cam profile in polar coordinates (r, ψ) from θ and γ. The variables d and σ (sigma) are known constants related to the geometry of the ankle prosthesis. The problem can be simplified in that the cam follower may be modeled as a point, as mentioned above. The final cam profile may require a perpendicular offset equal to the radius of the cam follower.

It cannot be assumed that a spring such as a fiberglass leaf spring behaves like a linear, translational spring. In the example of the prosthesis 201 shown in FIGS. 2A and 2B, the cam follower 254 is attached above the neutral plane of the spring 210, so the horizontal component of the force on the cam 250 creates a moment on the spring 210. Additionally, the cam follower 254 does not travel straight down as the leaf spring 210 deflects, but follows an arc about a virtual pivot. This virtual pivot point may be modeled as being at the simple support. Alternatively, a more accurate model of the virtual pivot point may be polycentric, dependent on the angle of the load, and somewhere between the simple support and the cam follower. Another source of series compliance is the flexure of the aluminum frame. Thus, without correction, the torque-angle curve may be less stiff than intended. Series compliance at the ankle joint may be modeled at the ankle joint, so that the moment on this compliance is equal to the moment on the ankle. The associated deflection is depicted in the figures as S. For example, the series compliance may be 1200 Nm/rad.

In an example, the cam profile may be determined by using a mathematical approach based on the principle of virtual work. The energy stored in the ankle joint is equal to the sum of the energy stored in the physical spring and the unwanted series stiffness, as reflected in Equation 1 below:

$\begin{matrix} {{\int_{0}^{\gamma}{M_{S}d\;\gamma}} = {{\int_{0}^{\theta}{M_{A}d\;\theta}} - {\int_{0}^{\delta}{M_{A}d\;{\delta.}}}}} & (1) \end{matrix}$

The plantarflexion and dorsiflexion regions may be individually solved, so the lower limit of integration is at the equilibrium position. The ankle moment M_(A) is defined as a function of θ, and the series stiffness experiences the same moment, so its associated deflection is reflected in Equation 2 below:

$\begin{matrix} {{\delta = \frac{M_{A}}{k_{2}}},} & (2) \end{matrix}$

At the equilibrium position θ=0°, the spring is preloaded a small angle γ₀. Equation 1 can be written as Equation 3, below:

$\begin{matrix} {{\int_{0}^{\gamma}{{k\left( {\gamma + \gamma_{0}} \right)}d\;\gamma}} = {{\int_{0}^{\theta}{M_{A}d\;\theta}} - {\int_{0}^{\delta}{M_{A}d\;{\delta.}}}}} & (3) \end{matrix}$

In Equation 3, k is the stiffness of the leaf spring (as a rotary spring). The left side of this equation may be integrated to:

$\begin{matrix} {{{\frac{1}{2}k\;\gamma^{2}} + {k\;\gamma_{0}\gamma} + c} = {{\int_{0}^{\theta}{M_{A}d\;\theta}} - {\int_{0}^{\delta}{M_{A}d\;{\delta.}}}}} & (4) \end{matrix}$

-   -   where c, the constant of integration, can be found to equal zero         from the initial conditions: θ=0, γ=0, δ=0. We then solve for γ         as a function of θ with the quadratic formula, so that

$\begin{matrix} {{\gamma(\theta)} = {{- \gamma_{0}} + \sqrt{\gamma_{0}^{2} + {\frac{2}{k}\left( {{\int_{0}^{\theta}{M_{A}d\;\theta}} - {\int_{0}^{\delta}{M_{A}d\;\delta}}} \right)}}}} & (5) \end{matrix}$

The integrals in Equation 5, which represent the work stored by the ankle and the series compliance, can be numerically solved, since we are specifying torque-angle relationship at the ankle. From γ, we can derive r, the radius of the cam profile at a given θ, from the defined geometry (via law of cosines) as: r(θ)=√{square root over (l ² +d ²−2ld cos(γ+σ))}  (6)

-   -   where σ is the angle between the initial position of the spring         and d, a line drawn between virtual spring centers. Since the         cam follower does not travel only vertically (see FIGS. 3A and         3B), we need to find ψ, in order to have a polar representation         of the cam profile as (ψ, r):         ψ(θ)=θ_(cam)−α=θ−δ−α  (7)     -   where α is the small angle between r and vertical, due to the         leaf spring not deflecting straight downward. We can         trigonometrically find α, using the geometry of the setup and         the law of sines:         α(θ)=sin⁻¹(L sin(σ+γ(θ)))+ω  (8)     -   where d and y are respectively the diagonal and vertical         distances between the ankle axis and virtual pivot of the         spring, and σ is the angle between the line d and the initial         position of the leaf spring. The numerical results, now in polar         coordinates as (r, ψ) from Equations 6 and 7, are converted to         Cartesian coordinates, and an offset curve corresponding to the         final cam profile is created with a perpendicular offset of the         cam follower radius.

FIG. 12 displays an enlarged view of the cam profile 252 with an outer edge that is shaped in accordance with the methods described above. The outer edge has a curved shape is comprised of a first portion 252 a, a second portion 252 b, and a third portion 252 c. The first portion 252 a is the portion against which the cam follower 254 rolls during plantarflexion of the prosthesis 201. The second portion 252 b is the portion in which the cam follower 254 is positioned during equilibrium (for instance, as shown in FIG. 2B). The third portion 252 c is the portion against which the cam follower 254 rolls during dorsiflexion of the prosthesis 201. As shown in FIG. 12, each section is curved, with second portion 252 b having a concave shape with reference to the cam follower 254, and first portion 252 a and third portion 252 c each having a concave shape with reference to the cam follower 254.

Choosing a cam profile. In an example, the cam profile 252 may be optimized for a 70 kg subject walking with the slider 220 positioned at 47% of the range of slider movement. According to the forward model, this position allowed an appropriate range of stiffnesses, higher and lower than what is needed for walking. The predicted range of stiffnesses and the desired primary stiffness curve for walking are plotted in FIG. 6. As shown in FIG. 6, a primary desired quasi-stiffness curve for walking is depicted in a dashed line, and the range of possible stiffnesses predicted for the range of positions of the slider 220 are indicated in the shaded are surrounding the dashed line.

Weight. In an example, the ankle, not including electronics, weighs 908 g. The electronics, which can be mounted more proximally on the prosthetic socket to reduce effects on the dynamics of leg swing, may weigh 170 g (including battery).

Stiffness Modulation. To minimize weight and size, the stiffness modulating mechanism was designed to only be utilized when no load is applied to the spring (other than a slight preload). FIG. 4A illustrates how moving the simple support towards the load increases spring stiffness. Experimental results of translational leaf spring stiffness is shown as a function of the slider position. Individual points in the graph in FIG. 4B represent tested positions. As shown in FIGS. 4A and 4B, as the slider position moves away from the beam support, the beam stiffness increases as shown, for example, in the graph shown in FIG. 4B.

The torque-angle relationship may be measured using a custom rotational dynamometer and the encoder 258 on the ankle joint 205. In an example, the dynamometer comprises a motor (BSM90N-3150AF, Baldor, Fort Smith, Ark.) and 6-axis load cell on the motor output (45E15A M63J, JR3, Inc., Woodland, Calif.). The ankle encoder may be sampled at 100 Hz by the onboard computer, and the load cell may be sampled at 1 kHz. The ankle may be fixed to a pyramid adapter on the dynamometer, and the ankle axis may be aligned with the axis of the dynamometer. The dynamometer can move the ankle at a constant speed in either plantarflexion or dorsiflexion up to and back from the peak angle over a period of eight seconds. The peak angle tested can be smaller at stiffer settings, so as not to overload the spring, cam follower, or frame. The test may be repeated at 10 slider positions across the slider's range of motion.

An experimental characterization of the stiffness profiles is shown in FIG. 7. The nine solid lines reflect testing on nine different slider positions across the range of motion of the slider 220. Dashed line 705 reflects the desired primary stiffness profile, which was designed for a slider position of 47%. Dashed line 710 reflects the experimentally determined profile at that slider position. Stiffness around 0° (measured as the average stiffness between −1° and 1°) at the highest stiffness level is 9.2 Nm/deg, and for the lowest stiffness level is 0.68 Nm/deg. Averaging across dorsiflexion trials, hysteresis resulted in a loss of only 1.9% of the energy stored.

The specific primary stiffness curve and primary slider position may be selected to balance several design features that may enhance clinical impact. A higher stiffness can improve standing stability, and a lower stiffness to improve range of motion during stair and ramp traversal. The selection of primary slider position governs how the stiffness profile can be varied from the primary stiffness profile. Thus, by selecting the primary slider position to be offset to either the anterior or posterior range of the spring, the available stiffness profiles can be shifted towards a more stiff or less stiff range, respectively. Thus, the primary stiffness profile and the selection of the primary slider position enables further customization of the mechanics, which may be altered depending on the design goals.

In an example, stiffness of the ankle can be modulated only during the swing phase of gait, or during static standing, when the ankle has negligible torque. By accepting this limitation, the sliding mechanism in the ankle can be built with no bearings or linear rails, because of the very low dynamic loads. The interface between the slider and frame may be comprised of two 1 mm thick pads of a high load thermoplastic, such as Delrin® (DuPoint USA, Wilmington, Del.), and the rolling contact with the spring rotates in high-load bushings. In particular, linear rails are significantly heavier, and the high static loads would prohibit the use of rails that could fit in the desired anatomical envelope. If the spring is compressed (by either a plantar- or dorsiflexion torque), friction between the roller and slider, or between the slider and Delrin pad, is too great for the motor to overcome.

Combining Intent Recognition. Adjusting ankle stiffness continuously during gait transitions may be achieved when using an intent recognition system, for instance, the kind described in U.S. Pat. No. 9,443,203 by Aaron Young and Levi Hargrove, titled Ambulation prediction controller for lower limb assistive device, incorporated herein by reference in its entirety. The computer 414 may execute the computer instructions used to recognize the intended ambulatory mode of the prosthesis 201, such as standing, walking, or traversing stairs. In other examples, a change in ambulation mode may be detected more simply, for instance using a decision table.

Advantages. The means of modulating stiffness described herein have several advantages. The range of stiffness profiles able to be implemented varies by an order of magnitude, due to the increasing rate of stiffness variation as the slider 220 moves posteriorly towards the heel 265. This nonlinearly increasing stiffness, coupled with the low inertia for slider 220, leads to a high stiffness modulation bandwidth. Additionally, by moving the slider 220 with a lead screw 232, which is non-backdriveable, the DC motor 230 is not required to maintain a holding torque, thus decreasing the electrical energy required for use of the prosthesis 201. Finally, the prosthesis 201 can be conveniently packaged in the anatomical envelope of the human foot-ankle complex, maintaining a cosmetic and low profile for amputees with longer residual limbs.

The simple mechanics of the prosthesis 201 improves robustness and avoids the more expensive actuation and transmission components that generally come with fully powered prostheses which add or dissipate energy. The prosthesis 201 is generally lighter than heavier fully powered prosthesis.

In another example, an ankle prosthesis is fully passive, thereby enabling the prosthesis to require no additional, outside power source or computing. This exemplary prosthesis may be made less expensively and may be used by a broader population. This example ankle prosthesis does not need to charge a battery. Additionally, it does not require an intent recognition algorithm that adjusts the ankle's mechanics automatically. The ankle prosthesis may have mechanics that are manually adjustable, for instance, by the user of the prosthesis. For example, the ankle prosthesis mechanics may be adjusted using a lever connected to a Bowden cable, which is a type of flexible cable used to transmit mechanical force by the movement of an inner cable relative to a hollow outer cable housing. This would allow the wearer to adjust the prosthesis mechanics to a setting (e.g. “stair setting”) manually at will.

FIG. 10 displays a side view of an exemplary ankle prosthesis 101. The prosthesis 101 employs several of the same designs as in prosthesis 201, including the cam-based transmission, its lightweight aspect, its ability to fit into an anthropomorphic physical envelope, and the design of the cam profile.

The prosthesis 101 comprises a lever transmission that permits the modification of the slider position by hand, circumventing the need for the small electric motor to adjust the position of the slider 120. As shown in FIG. 10, the lever transmission comprises a lever 130, a pulley block 131, a cable 132, a cable covering 133, and slider stoppers 166. Adjustment of the position of the lever 130 moves the slider along and beneath the leaf spring 110, which in turn, changes the ankle mechanics. At specific positions of the lever 130, the foot mechanics will change appropriately for different mobility tasks. For example, the lever transmission may include a lever setting for each task, including walking, standing, stair ascent/descent, and ramp ascent/descent. The lever 130 may be mounted anywhere for ease of access. For example, the lever 130 may be mounted on the ankle prosthesis 101, on the prosthetic pylon, on the socket, or on another location that the user can quickly and easily access throughout the day. The lever transmission enables movement of the slider, thereby allowing the user to change the ankle mechanics. For example, adjusting the position of the lever 130 causes the cable 132 to move around the pulley block 131. The slider 120 is affixed to a position on the cable 132 so that movement of the cable 132 causes the slider 120 to move along the length of the cable 132 between distal stopper 166 and proximal stopper 167.

In an exemplary prosthesis, the lever may comprise a Bowden cable transmission that adjusts the slider position. A Bowden cable transmission, which is similar to a bicycle cable, may be preferred due to the flexibility of lever location, simplicity, and robustness. The specific lever and Bowden cable implementation can be configured based on the distance needed to travel (about 6 cm), and the desired rotational range of the lever. The diameter of the cable can be minimal, since there is very little friction between the slider and the prosthesis frame due to the Teflon pads.

The use of a leaf spring system to assist in gait may be incorporated into other assistive devices, such as orthoses. For instance, an orthosis 500 is shown in FIG. 11 that provides support to a leg 530. The orthosis 500 comprises an upper brace 502, and a lower brace 518 coupled by a pivotable connector 520 that serves as an artificial ankle joint of the orthosis 500. A support member 506 may be attached to the upper brace 502 and a leaf spring 504. A motor 508 drives a screw 510, and a slider 512 comprising an outer portion 512 a and an inner portion 512 b is adjustable along at least a portion of the length of the screw 510. The leaf spring 504 is attached at its end with an encasement 514, encasing a cam follower 516 that rolls along a profile 517 while the orthosis 500 is in use during gait of the leg 530. The cam transmission comprising the cam follower 516 and the profile 517 enables a customizable nonlinear torque-angle curve. The shape of the profile 517 may be determined by using a mathematical approach based on the principle of virtual work as described above. As shown in FIG. 11, the shape of the profile 517 is curved and includes a concave portion in which the cam follower 516 is positioned while the orthosis is in an equilibrium position, and convex portions along which the cam follower 516 rolls while the orthosis 500 is assisting with plantarflexion and dorsiflexion. The slider 512 provides sliding support to shift this curve to be more or less stiff overall. In other examples, the cam transmission could be housed on the anterior, lateral, or posterior side of the shank of the orthosis. Integration of the cam transmission into an orthosis such as the orthosis 500 can improve gait and a range of other mobility tasks for a broad spectrum of patients using orthoses, such as stroke, spina bifuda, multiple sclerosis, and incomplete spinal cord injury. 

What is claimed is:
 1. A variable stiffness ankle system comprising; a first structural element; a second structural element; an ankle joint supporting the first structural element for plantarflexion and dorsiflexion rotation relative to the second structural element in phases of a gait cycle; a spring supported on the second structural element; and first and second cam members engaged for movement under the influence of one another, with the first cam member supported on the first structural element to rotate with the first structural element, and the second cam member engaging the spring to deflect the spring under the influence of the first cam member upon rotation of the first structural element, whereby the spring provides ankle stiffness by applying a restoring torque to resist rotation of the first structural element.
 2. A system as defined in claim 1, wherein the first structural element is a prosthetic ankle frame and the second structural element is a prosthetic foot frame.
 3. A system as defined in claim 1, wherein the first structural element is an orthotic foot brace and the second structural element is an orthotic leg brace.
 4. A system as defined in claim 1, further comprising a stiffness modulation unit configured to modulate the restoring torque applied by the spring.
 5. A system as defined in claim 4, wherein the stiffness modulation unit is configured to modulate stiffness of the spring.
 6. A system as defined in claim 4, wherein the spring comprises a leaf spring, the stiffness modulation unit is configured to vary a flexible length portion of the leaf spring, and the second cam member is engaged with the flexible length portion of the leaf spring.
 7. A system as defined in claim 6, wherein the stiffness modulation unit includes a slider supported for movement lengthwise of the leaf spring, and the flexible length portion of the leaf spring reaches from the slider to the second cam member.
 8. A system as defined in claim 7, wherein the leaf spring has a fixed end portion anchored to the second structural element, the leaf spring further has a free end portion opposite the fixed end portion, the second cam member engages the leaf spring proximate to the free end portion, and the slider is supported for movement along the leaf spring throughout a range of positions between the fixed end portion and the free end portion.
 9. A system as defined in claim 1, wherein the first structural element has an equilibrium position between a range of plantarflexion positions and a range of dorsiflexion positions.
 10. A system as defined in claim 9, wherein the spring is stressed upon rotation of the first structural element out of the equilibrium positon in either a plantarflexion or a dorsiflexion direction.
 11. A system as defined in claim 9, wherein the spring has a preloaded condition when the first structural element is in the equilibrium position.
 12. A variable stiffness ankle system comprising; an ankle frame; a foot frame; an ankle joint supporting the ankle frame for plantarflexion and dorsiflexion rotation relative to the foot frame in phases of a gait cycle; a spring supported on the foot frame; first and second cam members engaged for movement under the influence of one another, with the first cam member supported on the ankle frame to rotate with the ankle frame, and the second cam member engaging the spring to deflect the spring under the influence of the first cam member upon rotation of the ankle frame, whereby the spring provides ankle stiffness by applying a restoring torque to resist rotation of the ankle frame; and a stiffness modulation unit configured to modulate the restoring torque applied by the spring.
 13. A system as defined in claim 12, wherein the stiffness modulation unit is configured to modulate stiffness of the spring.
 14. A system as defined in claim 13, wherein the spring comprises a leaf spring, the stiffness modulation unit is configured to vary a flexible length portion of the leaf spring, and the second cam member is engaged with the flexible length portion of the leaf spring.
 15. A system as defined in claim 14, wherein the stiffness modulation unit includes a slider supported for movement lengthwise of the leaf spring, and the flexible length portion of the leaf spring reaches from the slider to the second cam member.
 16. A system as defined in claim 15, wherein the leaf spring has a fixed end portion anchored to the foot frame, the leaf spring further has a free end portion opposite the fixed end portion, the second cam member engages the leaf spring proximate to the free end portion, and the slider is supported for movement along the leaf spring throughout a range of positions between the fixed end portion and the free end portion.
 17. A system as defined in claim 12, wherein the ankle frame has an equilibrium position between a range of plantarflexion positions and a range of dorsiflexion positions.
 18. A system as defined in claim 17, wherein the spring is stressed upon rotation of the ankle frame out of the equilibrium positon in either a dorsiflexion or a plantarflexion direction.
 19. A system as defined in claim 17, wherein the spring has a preloaded condition when the ankle frame is in the equilibrium position.
 20. A variable stiffness ankle system comprising; a first structural element; a second structural element; an ankle joint supporting the first structural element for plantarflexion and dorsiflexion rotation relative to the second structural element in phases of a gait cycle; a spring supported on the second structural element; first and second cam members engaged for movement under the influence of one another, with the first cam member supported on the first structural element to rotate with the first structural element, and the second cam member engaging the spring to deflect the spring under the influence of the first cam member upon rotation of the first structural element, whereby the spring provides ankle stiffness by applying a restoring torque to resist rotation of the first structural element; a stiffness modulation unit configured to modulate the restoring torque applied by the spring; and a control system configured to monitor a flexion angle between the first and second structural elements, and to actuate the stiffness modulation unit in response to the flexion angle.
 21. A system as defined in claim 20, wherein the stiffness modulation unit is configured to modulate stiffness of the spring.
 22. A system as defined in claim 20, wherein the spring comprises a leaf spring, the stiffness modulation unit is configured to vary a flexible length portion of the leaf spring, and the second cam member is engaged with the flexible length portion of the leaf spring.
 23. A system as defined in claim 22, wherein the stiffness modulation unit includes a slider supported for movement lengthwise of the leaf spring, and the flexible length portion of the leaf spring reaches from the slider to the second cam member.
 24. A system as defined in claim 23, wherein the control system includes a motor configured to move the slider lengthwise of the leaf spring in response to the flexion angle. 